Single phase platinum aluminide bond coat

ABSTRACT

A thermal barrier coating system having an improved life as a result of a preoxidation treatment applied to a single phase platinum aluminide bond coat. After coating the substrate to form a diffusion platinum aluminum bond coat, the surface finish of the bond coat was grit blasted with an inert grit of preselected size at a preselected pressure to achieve a predetermined surface finish. After the grit blasting, but before application of the ceramic top coat of yttria-stabilized zirconia (YSZ), the coating was preoxidized to form a thin alumina scale by heat treating the diffusion platinum aluminide bond coat at an elevated temperature at a preselected partial pressure of oxygen.

FIELD OF THE INVENTION

The present invention is directed to improving the life of a thermalbarrier coating system used in hot environments, and more specifically,to improving the life of a thermal barrier coating system used inturbine applications by proper pretreatment of the bond coat prior toapplication of the ceramic topcoat.

BACKGROUND OF THE INVENTION

Improvements in manufacturing technology and materials are the keys toincreased performance and reduced costs for many articles. As anexample, continuing and often interrelated improvements in processes andmaterials have resulted in major increases in the performance ofaircraft gas turbine engines. Many of the improvements in gas turbineengines has been in extending the life expectancy of the turbinecomponents that are subjected to cyclic stresses at high temperatures incorrosive, oxidative environments. Extending the life expectancyincreases the mean service life of the components before replacement orrepair. This is a benefit to the operator of the aircraft that uses thegas turbine engines, as less “down time” for repairs or replacements isexperienced, resulting in an increase in operational time for revenuesservice.

Many of the parts used in the hot section of the turbine engine, such asturbine airfoils, are coated with thermal barrier coating systems. Thesesystems are subject deterioration as a result of the extreme serviceconditions in a hostile environment. Constant improvements are sought inthe life expectancy of thermal barrier coating systems to improve theperformance of the engine. These thermal barrier coating systems includehigh temperature superalloys that are coated with high temperatureceramic materials to improve their temperature capability. In order toimprove the adhesion of the ceramic material applied as a coating to thesubstrate, a bond coat is placed between the substrate and the ceramictop coating. Various bond coats have been used including MCrAlY's anddiffusion aluminides.

Preoxidation of MCrAlY bond coats prior to application of a thermalbarrier layer to form a thin alumina layer by in-situ oxidation of theMCrAlY layer using a commercially pure hydrogen atmosphere at 1975° F.has been found to improve the adhesion of the ceramic layer as set forthin U.S. Pat. No. 4,414,249 to Ulion et al. The preoxidation is precededby polishing of the MCrAlY. While the polishing step was important, thetechnique was not felt to be important and could be accomplishedmechanically electrochemically or chemically.

U.S. Pat. No. 5,238,752 to Duderstat et al. teaches the formation of athin coating of alumina over a diffusion aluminide coating during theheating step which is part of the deposition process for the ceramiccoating. Heating to a temperature of about 1800° F. is accomplished in avacuum chamber in an atmosphere of about 5×10⁻⁵ Torr to produce acoating thickness of about 2×10⁻⁵ inches.

Others have discussed similar formation of a protective alumina coatingby using a low partial pressure oxygen atmosphere during thermaltreatment. Exemplary teachings include U.S. Pat. No. 5,716,720 toMurphy, which teaches formation of the alumina layer by evacuating avacuum furnace to 10⁻⁶ Torrs before backfilling the furnace with Arduring a heat treatment of 1975° F. Rickerby et al. in U.S. Pat. No.5,763,107 teaches the formation of the alumina layer during theformation of the ceramic coating after evacuation at a pressure of about10⁻⁵ Torr, the dissociation of the ceramic during the EB application ofthe zirconia contributing to the oxidation of the bond coat. Rickerby etal. also teaches the optional intentional addition of oxygen duringapplication of the ceramic top coat.

Myriad other teachings of formation of an alumina over a bond coat,whether a MCrAlY or a diffusion aluminide or a superalloy substrateexist. Even when protective atmospheres are formed, the formation of analumina layer thus appears to be incidental to subsequent hightemperature exposure of an outer layer that contains a perceivablequantity of aluminum, which is a fundamental part of the composition ofMCrAlY diffusion aluminides and superalloy substrates. These generalapproaches describe the formation of a “pure” alumina by CVD depositionor its thermal growth under carefully controlled atmospheres to achieveoxide thicknesses of 0.25-25 microns.

These teachings indicate that there are a number of considerations inthe formation of oxide over the layer underlying the ceramic top coat.Among these considerations is the completion of oxide phasetransformation from transient oxides to a dense alpha alumina. Also tobe considered is the purity of the oxide formed. The kinetics of thetransition from internal to external oxidation as well as the formationof a “defect free” contiguous layer may also contribute to the successof oxide formation in a particular system. Other system-specific factorsmay include the columnar oxide grain structures and oxide growth byinward diffusion with no lateral oxide growth.

Despite the large number of teachings of the benefit of the formation ofan alumina layer over a bond coat prior to the application of a ceramictop coat, and the perceived novelty of forming such alumina layers usingvarious processing techniques, the formation of an alumina layer isincidental to subsequent high temperature exposure of an outer layerthat includes some aluminum. It is clear, however, that there are otherfactors that contribute to the inevitable and incidental formation ofalumina at elevated temperatures, and that the complexity of theformation of this alumina in varying and different compositions is not,and has not been, well understood. To achieve a “good” alumina coating,the complexity of the process of oxide film formation must be taken intoconsideration, along with other seldom discussed and interrelatedfactors such as the chemical composition of the surface that willunderlie the ceramic top coat, whether substrate material or asubsequently applied bond coat, coating microstructure as well assurface conditions. The formation of acceptable alumina is very specificto the coating system and the interrelationship of these factors.

What is needed are advanced coatings in which these various interrelatedfactors are understood so that coating systems can yield longer lifeexpectancies or higher temperature capabilities.

SUMMARY OF THE INVENTION

The present invention provides a thermal barrier coating system havingan improved life as a result of a preoxidation treatment applied to abond coat. After coating the substrate with platinum and forming adiffusion platinum aluminum bond coat, the surface finish of the bondcoat was grit blasted with an inert grit of preselected size at apreselected pressure to achieve a predetermined surface finish. Afterthe grit blasting, but before application of the ceramic top coat ofyttria-stabilized zirconia (YSZ), the coating was preoxidized to form athin alumina scale by heat treating the diffusion platinum aluminidebond coat at a preselected elevated temperature at a preselected partialpressure of oxygen.

Additionally the preoxidation heat treatment of the bond coating isperformed at a specified rate, no slower than about 45 minutes to spanthe temperature range from ambient or near ambient to at least about1090° C. (2000° F.). Application of the ceramic top coat over theplatinum aluminide bond coat having a thermally grown oxide film isperformed at a temperature of no lower than about 850° C. (1560° F.)using a physical vapor deposition method.

While the processes and treatments set forth herein generally areapplicable to the diffusion platinum aluminides of thermal barriercoating system of the present invention, it is recognized that theseparameters may well be ineffective in other thermal barrier systems inproducing the pure alumina bond coat required to improve the FTC life,and hence the performance of a different thermal barrier system may notachieve the same beneficial results using these parameters. Indeed, adifferent thermal barrier system could conceivably be degraded bysimilar parameters.

As used herein, the term “platinum aluminide,” (PtAl), encompassesunmodified platinum aluminide and modified platinum aluminides, providedhowever that the basic single phase structure of the aluminide ismaintained. When applied over nickel-based superalloy substrates, these“platinum aluminides” form single phase platinum-nickel aluminides,PtNiAl, and this structure is also encompassed within the term platinumaluminide. The term “aluminum oxide” (alumina) as used hereinencompasses unmodified aluminum oxide as well as modified forms ofaluminum oxide containing small amounts of additional elements such asnickel, cobalt, chromium or other elements. Elements such as nickel andchromium may then form other oxides such as chromium oxide or nickeloxide. These elements may be present in the oxide as a result ofdiffusion from the substrate or as modifiers intentionally added to thebond coat. The term “pure alumina oxide” does not include chromiumoxides or nickel oxides. The terms “partial pressure of oxygen” or“oxygen partial pressure” are used interchangeably and mean either apartial pressure of pure oxygen intentionally flowing through thefurnace as measured by an oxygen gage, or by premixing oxygen with aninert gas, such as argon, in known, ascertainable ratios and flowing themixture through the furnace. These partial pressures of oxygen arecontrolled within the prescribed limits.

Other features and advantages of the present invention will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a SEM cross-sectional view of internal oxidation and whiskersindicating outward diffusion of aluminum in the alumina layer formed ina two-phase PtAl coating preoxidized at 10⁻⁵ mbar.

FIG. 2 is a graph showing the effects of the partial pressure of oxygenduring preoxidizing treatment on the FCT life of a coating made inaccordance with the present invention.

FIG. 3 is a graph showing the effect of preoxidizing temperature on theFCT life of a single phase PtAl coating.

FIG. 4 is a graph showing the effect of temperature on the FCT life of atwo phase PtAl coating.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is generally applicable to components formed fromsuperalloys used in the hot portions of turbine engines to which thermalbanrer coating systems are applied to improve their temperaturecapability. Such components are subjected to very high temperatures aswell as severe oxidation and corrosion, thermal stresses and thermalcycling. These components most typically include high and low pressureturbine airfoils, such as turbine blades and turbine vanes. Otherapplicable components include shrouds, combustor liners and augmentorhardware.

The superalloy hardware of the present invention is coated with a singlephase platinum aluminide bond coat. The type of superalloy is not acritical factor in the present invention, and an additional coating suchas a diffusion barrier may even be imposed between the superalloysubstrate and the bond coat if desired, so as to minimize the effect ofelemental diffusion between the superalloy substrate and the bond coat.In preferred embodiments, the superalloy substrate materials arenickel-based superalloys, and in the most preferred embodiments, thenickel-based superalloy substrate material is René N5.

The bond coat of the present invention is a single phase platinumaluminide bond coat. While there are several ways of achieving aplatinum aluminide bond coat, the preferred method of forming the bondcoat is to deposit a layer of platinum over the substrate article. Thiscan be performed by a chemical vapor deposition method (CVD), but ispreferably applied by an electro-deposition technique such aselectroplating. The aluminide may be developed in accordance with anumber of well known techniques, which include exposing the platinumcoated surface to a vapor phase aluminum. Once again, this may involveCVD, or the well-known pack processed or over-the-pack processes. Asthese are elevated temperature processes, the fill development of theplatinum aluminide may require some additional time at an elevatedtemperature, as is well known in the art.

Following formation of the single phase diffusion platinum aluminide,the diffusion platinum aluminide coating is provided with a surfacefinish between about 16 R_(a) and 125 R_(a). Preferably, the coating isgrit blasted using alumina grit having a grit classification from #60 to#1200. The preferred grit size is #80. The pressure utilized in the gritblasting procedure is performed at between 30-100 psi, but preferablybetween about 60-80 psi. The grit blasting produces an average surfacefinish of between about 32 R_(a) and 63 R_(a), preferably about 50R_(a). As will be discussed below, a chemical treatment of the platinumaluminide of the coating of the present invention did not produce thebeneficial results obtained with the grit-blasting techniques requiredby the present invention. Grit blasting of the single phase difflusionplatinum aluminide coating is an essential element in the success of thethermal barrier coating of the present invention. It is believed thatgrit blasting achieves a uniform and “clean surface chemistry.” Gritblasting removes up to 2 microns of material from the surface. Allsurface contaminants are removed, as well as localized surfaceconcentration gradients of Pt, Al and Ni.

Following the treatment of the surface finish of the single phasediffusion platinum aluminide bond coat, the article is given apreoxidation heat treatment. The parameters of the preoxidation heattreatment are carefully controlled to produce the desired thin, purealumina film of the present invention. The fundamental parametersinclude the partial pressure of oxygen, the heating rate and thetemperature range of the preoxidation heat treatment. To form thedesired oxide, a partial pressure of no lower than 10⁻⁵ mbar of oxygenis required. However, the maximum partial pressure of oxygen is about1000 Mbar. When the platinum aluminide bond coat is preoxidized at apartial pressure of oxygen of about 10⁻⁴ mbar, a coating system havingthe best FCT life is produced. The rate of heating the coated articlerequires heating from near ambient temperature to the preoxidationtemperature within about 45 minutes. Preferably, the heating isperformed in a time range of about 11-15 minutes. The preoxidation isperformed in the temperature range of 982° C. -1150° C. (1800° F.-2100°F.), and preferably at about 1121° C. (2050° F.).

It is an important aspect of the present invention to perform thepreoxidation within the above parameters. Analysis of oxides formedusing parameters outside these ranges yielded variations from oxidesformed using these parameters. Scanning electron microscopy (SEM) anddepth profiling of the formed oxides for chemical composition of theoxides by XPS techniques disclosed these variations. Non-uniformmicrostructures resulted when there were high oxygen pressures, that isabove about 1000 Mbar. The non-uniform microstructures were exacerbatedwhen elements other than aluminum were present in the oxide. Oxygenpressures within the range of the present invention yielded compact“ridge” type microstructures characteristic of alpha-alumina again whenno elements other than aluminum were present in the oxide. Low partialpressures of oxygen, below 10⁻⁵ mbars, could result in internaloxidation along with an outward diffusion of aluminum. This structureinitially became evident during preoxidation heat treatment of two phasePtAl coatings that were preoxidized at partial pressures of about 10⁻⁵mbar, and is expected to become more prevalent as the partial pressureof oxygen is further reduced. This structure is expected to yield a pooradhesion of the oxide to the bond coat. Extensive internal oxidationwith growth of oxide “whiskers” pointing to the outward diffusion ofaluminum is shown in FIG. 1. While the two phase PtAl coatingpreoxidized at 10⁻⁵ mbars did display this extensive internal oxidation,likely because of the presence of fine grains of the second phase at thesurface of the two phase PtAl coating that provides short paths for theinward diffusion of oxygen and the outward diffusion of aluminum, asingle phase PtAl coating similarly preoxidized did not display thisoxidation.

The rate of heating the coated article is also a factor. If the rate ofheating is performed too slowly, there is an opportunity for detrimentaloxide phases to form within the oxide layer at intermediatetemperatures. As these other oxide layers are not as adherent as thepure alumina and since they intermix with the pure alumina forming anoverall oxide layer that is not pure, the resulting oxide layer is notas adherent and will have a reduced life as it peels from the PtAlsurface much more quickly than a pure alumina.

While the temperature of preoxidation is important, it is specific to aparticular bond coat, and therefore to a particular thermal barriercoating system. A successful preoxidation of one preselected bond coatforms an acceptable oxide at a given temperature, but a different bondcoating system, while it may oxidize, does not form the best possiblecoating system at the same preoxidation temperature. This is best seenby reference to FIGS. 3 and 4. FIGS. 3 and 4 shows the FCT life cycleresults of two different coating compositions when oxidized at varioustemperatures in the temperature range of about 1940-2100° F. The firstcoating shown in FIG. 3 withstands the highest cycles to failure whenpreoxidized at a temperature in the range of about 2090-2100° F. Thenumber of cycles is reduced when the preoxidation is performed at lowertemperatures. When a different second coating is given the samepreoxidation treatment, different fatigue life results occur. As shownin FIG. 4, the second coating withstands the highest cycles to failurewhen preoxidized at a temperature of about 2000° F. The performance ofthe first coating at this preoxidation temperature is well below thepeak values in the temperature in the range of about 2090-2100° F. Thecoating of FIG. 1 is a single phase Pt(Ni)Al coating that produced thedata set forth in FIG. 3. The coating that produced the data set forthin FIG. 4 is a two phase Pt(Ni)Al coating, the coating having a higheraluminum content than the single phase coating, and further includingprecipitates of a second phase of Pt_(x)Al_(y).

Once the pure alumina film or coating is formed over the PtAl bond coat,a 7-YSZ ceramic top coat is applied over it. The method of applying thisceramic top coat is well-known in the art, and any physical vapordeposition (PVD) process may be used to apply the ceramic top coat.

EXAMPLE 1

René N5 substrates were coated with a single phase PtAl bond coat andgrit blasted with #60 alumina grit at 80 psi to achieve an averagesurface roughness of about 50 Ra. The substrates were then heat treatedat an oxygen partial pressures of 10⁻⁶ mbar, 10⁻⁵ mbar, 10⁻⁴ mbar and1000 Mbars at about 2050° F. for about 2-4 hours. Following the partialpressure oxidation, the samples were provided with a standard 7-YSZceramic topcoat with an electron beam physical vapor deposition (EBPVD)process. The samples were given a one hour FCT cycle test at about 2125°F. The results are provided in FIG. 2. The baseline for samples having asingle phase bond coat, being grit blasted but not having a partialpressure heat treatment, is 230 cycles. The partial pressurepreoxidation improves the fatigue cycle life over the baseline sample.

EXAMPLE 2

René N5 substrates were coated with a single phase PtAl bond coat anddivided into two groups. The surface of the first group was grit blastedwith #60 alumina grit at a pressure of 80 psi. The second group was acidetched in a solution of hydrochloric acid (HCl) and nitric acid (HNO₃)for a time of about ten (10) seconds at room temperature. Thecleanliness of the surfaces of the substrates after surface treatment ofeach procedure was verified by Auger surface analysis. Both groups ofsamples were then preoxidized at oxygen partial pressures of 10⁻⁴ mbarand 10⁻⁵ mbar at temperatures of about 2050° F. The samples were thencoated with a standard 7-YSZ ceramic topcoat in the manner set forth inExample 1 and tested in accordance with the testing performed inExample 1. The acid treated group performed in accordance with thebaseline samples that were single phase bond coated, being grit blastedbut not having a partial pressure heat treatment. The FCT life of theacid treated group was in the range of about 230 cycles. The FCT life ofthe group that was grit blasted was similar to the performance of thesamples in Example 1 and FIG. 2 that were grit blasted and provided witha preoxidation partial pressure heat treatment at pressures of 10⁻⁴ mbarand 10⁻⁵ mbar.

Based on the results of the above testing as provided in FIG. 2, boththe pretreatment of the surface of the sample having a platinumaluminide prior to a preoxidation as well as the partial oxygen pressureof a preoxidation heat treatment are factors in FCT performance.Preoxidation heat treatment of the samples alone is insufficient toprovide a beneficial effect to the samples. This is evident from thetest results of Example 2, in which no beneficial effect in FCTperformance from a partial pressure preoxidation heat treatment wasobserved in those samples that were acid etched. However, samples havinga surface that was grit blasted prior to a partial pressure preoxidationheat treatment did show an improved FCT performance. The FCTperformance, however, did increase to a maximum at a partial pressure ofabout 10⁻⁴ millibars of oxygen, and decreased as the partial pressure ofoxygen was further reduced. Thus, FCT performance is influenced not onlyby a partial pressure heat treatment of oxygen, but also by surfacetreatment of the PtAl bond coat prior to the heat treatment, the rate ofheating to preoxidized the surface and the temperature of thepreoxidation.

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

1-18. (canceled)
 19. A gas turbine component having at least a portionof an outer surface coated with a ceramic thermal barrier system thathas a single phase platinum aluminide coating with a pure alumina layerformed with a method comprising the steps of: providing a gas turbinecomponent for use at high temperatures; applying a thin layer ofplatinum to at least a portion of a surface of the component; forming asingle phase platinum aluminide on the surface of the component byexposing the thin layer of platinum to a source of aluminum for apreselected time; then, producing a surface of the single phase platinumaluminide having a surface finish between about 16 microinches R_(a) and125 microinches R_(a); cleaning the single phase platinum aluminide toprovide a surface free of oxides, contaminants and local gradients ofnickel, aluminum and platinum; then, preoxidizing the single phaseplatinum aluminide by heating the component in a preselected partialpressure of oxygen, wherein the preoxidation is accomplished by heatingthe component to a preselected temperature at a preselected rate so asto form a thin layer of pure alumina over the single phase platinumaluminide; followed by, applying a ceramic top coat over the thin layerof pure alumina.
 20. The gas turbine component of claim 19, wherein thestep of forming a single phase platinum aluminide by exposing the thinlayer of platinum to a source of aluminum for a preselected timeincludes exposing the thin layer of platinum to a source of vapor phasealuminum for sufficient time and at a sufficiently high temperature toform a single phase platinum aluminide.
 21. The gas turbine component ofclaim 19 wherein the step of preoxidizing the single phase platinumaluminide is accomplished by heating the component in a vacuum furnaceat a partial pressure of oxygen between 1000 Mbar and 10⁻⁵ mbar.
 22. Thegas turbine component of claim 20 wherein the step of preoxidizing thesingle phase platinum aluminide is accomplished by heating the componentin a vacuum furnace at a partial pressure of oxygen between 1000 Mbarand 10⁻⁵ mbar.
 23. The gas turbine component of claim 19 wherein thepure alumina layer is formed at a preselected temperature is in therange of about 1800° F. to about 2100° F.
 24. The gas turbine componentof claim 20 wherein the pure alumina layer is formed at a preselectedtemperature is in the range of about 1800° F. to about 2000° F.
 25. Themethod of claim 19 wherein the step of applying a ceramic top coat usesa PVD technique over the thin layer of pure alumina by applying theceramic top coat within a preselected temperature range includesapplying a yttria-stabilized zirconia using EB-PVD.
 26. A gas turbinecomponent comprising: a superalloy substrate having a surface; a singlephase platinum aluminide bond coat having a surface on at least aportion of the surface of the substrate, the platinum aluminide bondcoat having a surface, the bond coat surface being free of contaminantsand local gradients of nickel, aluminum and platinum; a pure aluminalayer having a compact microstructure overlying the surface of theplatinum aluminide bond coat, the bond coat surface being free of oxidesother than the pure alumina; and a ceramic top coat overlying the purealumina layer.
 27. The gas turbine component of claim 26, wherein thebond coat surface has a roughness in the range of about 16 microinchesR_(a) and about 125 microinches R_(a).
 28. The gas turbine component ofclaim 26, wherein the superalloy is a nickel-based superalloy.
 29. Thegas turbine component of claim 26, wherein the superalloy is René N5.30. The gas turbine component of claim 26, wherein a diffusion barrieris imposed between the superalloy substrate and the bond coat.
 31. Thegas turbine component of claim 27, wherein the superalloy is anickel-based superalloy.
 32. The gas turbine component of claim 27,wherein the superalloy is René N5.
 33. A gas turbine component having atleast a portion of an outer surface coated with a ceramic thermalbarrier system that has a single phase platinum aluminide coating with apure alumina layer formed with a method comprising the steps of:providing a gas turbine component for use at high temperatures; applyinga thin layer of platinum to at least a portion of a surface of thecomponent; forming a single phase platinum aluminide on the surface ofthe component by exposing the thin layer of platinum to a source ofaluminum for a preselected time; grit blasting the single phase platinumaluminide using a grit of preselected size at a preselected pressure fora time sufficient to achieve a preselected surface finish; preoxidizingthe single phase platinum aluminide by heating the component in apartial pressure of oxygen between 10⁻⁵ mbar and 1000 Mbar, wherein thepreoxidation is accomplished by heating the component to a preselectedtemperature at a preselected rate so as to form a thin layer of purealumina over the single phase platinum aluminide; followed by, applyinga ceramic top coat over the thin layer of pure alumina.
 34. The gasturbine component of claim 33, wherein the step of forming a singlephase platinum aluminide by exposing the thin layer of platinum to asource of aluminum for a preselected time includes exposing the thinlayer of platinum to a source of vapor phase aluminum for sufficienttime and at a sufficiently high temperature to form a single phaseplatinum aluminide.
 35. The gas turbine component of claim 33, whereinthe step of grit blasting the single phase platinum aluminide using agrit of preselected size at a preselected pressure includes selecting analumina grit having a size classification from about #60 to about #120.36. The gas turbine component of claim 35, wherein the step of gritblasting the single phase platinum aluminide using a grit of preselectedsize at a preselected pressure includes selecting an alumina grit havinga size classification of about #80.
 37. The gas turbine component ofclaim 33, wherein the step of preoxidizing the single phase platinumaluminide by heating includes heating the component in a partialpressure of oxygen of about 10⁻⁴ mbar.
 38. The gas turbine component ofclaim 35, wherein the step of preoxidizing the single phase platinumaluminide by heating includes heating the component in a partialpressure of oxygen of about 10⁻⁴ mbar.
 39. A method for coating a gasturbine component with a thermal barrier coating system by a controlledpreoxidation heat treatment, comprising the steps of: providing a gasturbine component for use at high temperatures; applying a thin layer ofplatinum to at least a portion of a surface of the component; forming asingle phase platinum aluminide on the surface of the component byexposing the thin layer of platinum to a source of aluminum for apreselected time; grit blasting the single phase platinum aluminideusing a grit of preselected size at a preselected pressure for apreselected period of time to achieve a preselected surface finish;then, preoxidizing the single pahse platinum aluminide by heating thecomponent in at a preselected partial pressure of oxygen between 10⁻⁵mbar and 1000 Mbar, wherein the preoxidation is accomplished by heatingthe component to a preselected temperature at a preselected rate so asto form a thin layer of pure alumina over the single phase platinumaluminide; followed by, applying a ceramic top coat over the thin layerof pure alumina.
 40. The method of claim 39, wherein the step ofpreoxidizing the single phase platinum aluminide the component at apreselected partial pressure of oxygen between 10⁻⁵ mbar and 1000 Mbarincludes heating the component at a preselected partial pressure ofoxygen of about 10⁻⁴ mbar.